Headliner with integrally-molded energy distribution zone

Abstract

A vehicular interior trim component, such as a headliner, includes a core having an exterior surface with at least one integrally-molded energy distribution zone. The at least one integrally-molded energy distribution zone may be embossed from the exterior surface of the core. Alternatively, the at least one integrally-molded energy distribution zone may be recessed in the exterior surface of the core. The integrally-molded energy distribution zone may have a generally sinusoidal cross-sectional shape to enable energy absorption from any direction.

1 . A vehicular interior trim component, comprising: 
 a core made of foam material having an exterior surface with at least one integrally-molded energy distribution zone comprising a series of undulations.    
   
   
       2 . The vehicular interior trim component according to  claim 1 , wherein the at least one integrally-molded energy distribution zone is embossed from the exterior surface.  
   
   
       3 . The vehicular interior trim component according to  claim 1 , wherein the at least one integrally-molded energy distribution zone is recessed within the exterior surface.  
   
   
       4 . The vehicular interior trim component according to  claim 1 , wherein the integrally-molded energy distribution zone has a generally sinusoidal cross-sectional shape.  
   
   
       5 . The vehicular interior trim component according to  claim 1 , wherein the core comprises urethane material.  
   
   
       6 . The vehicular interior trim component according to  claim 5 , wherein the urethane material includes fiberglass reinforcing fibers.  
   
   
       7 . The vehicular interior trim component according to  claim 1 , wherein the vehicular interior trim component comprises a headliner.  
   
   
       8 . A headliner, comprising: 
 a core made of foam material having an exterior surface with at least one integrally-molded energy distribution zone comprising a series of undulations.    
   
   
       9 . The headliner according to  claim 8 , wherein the at least one integrally-molded energy distribution zone is embossed from the exterior surface.  
   
   
       10 . The headliner according to  claim 8 , wherein the at least one integrally-molded energy distribution zone is recessed within the exterior surface.  
   
   
       11 . The headliner according to  claim 8 , wherein the integrally-molded energy distribution zone has a generally sinusoidal cross-sectional shape.  
   
   
       12 . The headliner according to  claim 8 , wherein the core comprises urethane material.  
   
   
       13 . The headliner according to  claim 12 , wherein the urethane material includes fiberglass reinforcing fibers.  
   
   
       14 - 17 . (canceled)  
   
   
       18 . A headliner, comprising: 
 a core made of thermoset foam material having an exterior surface with at least one integrally-molded energy distribution zone having a cellular structure comprising a series of undulations.    
   
   
       19 . The headliner according to  claim 18 , wherein the at least one integrally-molded energy distribution zone is embossed from the exterior surface.  
   
   
       20 . The headliner according to  claim 18 , wherein the at least one integrally-molded energy distribution zone is recessed within the exterior surface.  
   
   
       21 . The headliner according to  claim 18 , wherein the integrally-molded energy distribution zone has a generally sinusoidal cross-sectional shape.  
   
   
       22 . The headliner according to  claim 18 , wherein the core comprises urethane material.  
   
   
       23 . The headliner according to  claim 22 , wherein the urethane material includes fiberglass reinforcing fibers.  
   
   
       24 . The headliner according to  claim 18 , wherein the at least one integrally-molded energy distribution zone is substantially uniform in density.  
   
   
       25 . The headliner according to  claim 1 , wherein the at least one integrally-molded energy distribution zone is substantially uniform in density.  
   
   
       26 . The headliner according to  claim 8 , wherein the at least one integrally-molded energy distribution zone is substantially uniform in density.